Tuesday, October 7, 2014

Conclusions

National fatality data indicate that the three
most common forklift-related fatalities involve forklift overturns,
workers on foot being struck by forklifts, and workers falling from
forklifts. The case studies indicate that the forklift, the factory
environment, and actions of the operator can all contribute to fatal
incidents involving forklifts. In addition, these fatalities indicate
that many workers and employers are not using or may be unaware of
safety procedures and the proper use of forklifts to reduce the risk of
injury and death.

Recommendations

Employers

Reducing
the risk of forklift incidents requires a safe work environment, a safe
forklift, comprehensive worker training, safe work practices, and
systematic traffic management.
NIOSH recommends that employers and
workers comply with OSHA regulations and consensus standards, maintain
equipment, and take the following measures to prevent injury when
operating or working near forklifts.

Worker Training

Make sure that workers do not operate a forklift unless they have been trained and licensed.

Develop,
implement, and enforce a comprehensive written safety program that
includes worker training, operator licensure, and a timetable for
reviewing and revising the program. A comprehensive training program is
important for preventing injury and death. Operator training should
address factors that affect the stability of a forklift—such as the
weight and symmetry of the load, the speed at which the forklift is
traveling, operating surface, tire pressure, and driving behavior.

Inform
operators of sit-down type forklifts that they can be crushed by the
overhead guard or another part of the truck after jumping from the
overturning forklift. The operator of a sit-down type forklift should
stay with the truck if lateral or longitudinal tip over occurs. The
operator should hold on firmly and lean away from the point of impact.

Train
operators of stand-up type forklifts with rear-entry access to exit
from the truck by stepping backward if a lateral tip over occurs.

Ensure
that operator restraint systems are being used on sit-down type
forklifts. Since 1992, forklift manufacturers have been required to
equip new sit-down type forklifts with operator restraint systems. Many
manufacturers of these forklifts offer restraint systems that can be
retrofitted on older forklifts. Many of the fatalities resulting from
overturns of sit-down type forklifts might have been prevented if the
operator had been restrained. The overhead guard of the forklift is
generally the part that crushes the operator's head or torso after he or
she falls or jumps outside of the operator's compartment. The risk of
being crushed by the overhead guard or another rigid part of the
forklift is greatly reduced if the operator of a sit-down type forklift
remains inside the operator's compartment. Because many forklifts are
not equipped with a restraint system and operator compliance is less
than 100% on forklifts equipped with a restraint system, operators
of sit-down type forklifts should be instructed not to jump from the
operator's compartment but to stay inside by leaning in the opposite
direction of the overturn.

Train operators to handle asymmetrical loads when their work includes this activity.

Forklift Inspection and Maintenance

Establish a vehicle inspection and maintenance program.

Retrofit old sit-down type forklifts with an operator restraint system if possible.

Lifting

Ensure
that operators use only an approved lifting cage and adhere to general
safety practices for elevating personnel with a forklift. Also, secure
the platform to the lifting carriage or forks.

Provide means for
personnel on the platform to shut off power to the truck whenever the
truck is equipped with vertical only or vertical and horizontal controls
for lifting personnel.

Workers on Foot

Separate forklift traffic and other workers where possible.

Limit some aisles to workers on foot only or forklifts only.

Restrict
the use of forklifts near time clocks, break rooms, cafeterias, and
main exits, particularly when the flow of workers on foot is at a peak
(such as at the end of a shift or during breaks).

Install physical barriers where practical to ensure that workstations are isolated from aisles traveled by forklifts.

Evaluate
intersections and other blind corners to determine whether overhead
dome mirrors could improve the visibility of forklift operators or
workers on foot.

Make every effort to alert workers when a
forklift is nearby. Use horns, audible backup alarms, and flashing
lights to warn workers and other forklift operators in the area.
Flashing lights are especially important in areas where the ambient
noise level is high.

Work Environment

Ensure
that workplace safety inspections are routinely conducted by a person
who can identify hazards and conditions that are dangerous to workers.
Hazards include obstructions in the aisle, blind corners and
intersections, and forklifts that come too close to workers on foot. The
person who conducts the inspections should have the authority to
implement prompt corrective measures.

Install the workstations,
control panel, and equipment away from the aisle when possible. Do not
store bins, racks, or other materials at corners, intersections,or other
locations that obstruct the view of operators or workers at
workstations.

Enforce safe driving practices such as obeying
speed limits, stopping at stop signs, and slowing down and blowing the
horn at intersections.

Repair and maintain cracks, crumbling edges, and other defects on loading docks, aisles, and other operating surfaces.

Workers

Do not operate a forklift unless you have been trained and licensed.

Use seatbelts if they are available.

Report to your supervisor any damage or problems that occur with a forklift during your shift.

Do
not jump from an overturning, sit-down type forklift. Stay with the
truck if lateral or longitudinal tip over occurs. Hold on firmly and
lean in the opposite direction of the overturn.

Exit from a stand-up type forklift with rear-entry access by stepping backward if a lateral tip over occurs.

Use extreme caution on grades, ramps, or inclines. Normally you should travel only straight up and down.

On all grades, tilt the load back if applicable, and raise it only as far as needed to clear the road surface.

Do not raise or lower the forks while the forklift is moving.

Do not handle loads that are heavier than the rated weight capacity of the forklift.

Operate the forklift at a speed that will permit it to be stopped safely.

Slow down and sound the horn at intersections and other locations where vision is obstructed.

Look toward the path of travel and keep a clear view of it.

Do not allow passengers to ride on forklift trucks unless a seat is provided.

When dismounting from a forklift, always set the parking brake, lower the forks, and neutralize the controls.

Do not drive up to anyone standing in front of a bench or other fixed object.

Do not use a forklift to elevate workers who are standing on the forks.

Do not elevate a worker on a platform unless the vehicle is directly below the work area.

Whenever a truck is used to elevate personnel, secure the elevating platform to the lifting carriage or forks of the forklift.

Use
a restraining means such as rails, chains, or a body belt with a
lanyard or deceleration device for the person(s) on the platform.